Flexible Fiber Optic Pins for Angular Alignment Error Compensation

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Solution Overview

Problem

Existing fiber optic connectors face challenges in accommodating angular and diametral errors between ferrules, leading to imperfect mating geometry and potential damage or misalignment during connection, which can result in suboptimal optical signal transmission and structural failure.

Innovation Solution

The introduction of flexible pins in fiber optic connectors that can bend and radially deform to accommodate errors, allowing for secure mating with a force of less than 15 Newtons, and a latch mechanism for easy installation and removal without disassembling the ferrule from the connector housing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If rigid pins are used to align ferrules, then alignment precision is improved, but the risk of damage from angular and diametral errors increases

Engineering Contradiction:

Improvealignment precisionVSAvoiddamage risk from errors

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The pin is designed with variable flexibility parameters - sufficiently flexible to accommodate angular and diametral errors without damage, yet sufficiently rigid to maintain alignment precision. This is achieved through specific material selection and geometric design of the pin structure.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The flexible pin acts as an intermediary element between the two ferrules, absorbing geometric errors through controlled deformation while still enabling precise fiber alignment. The pin mediates the connection by adapting to imperfect ferrule geometry rather than requiring perfect geometry.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If flexible pins are used to accommodate errors, then reliability is improved, but alignment precision may deteriorate

Engineering Contradiction:

Improveconnection reliabilityVSAvoidalignment precision

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The pin's flexibility parameters are optimized to fall within a specific range that simultaneously ensures reliable accommodation of errors and maintains sufficient alignment precision. The design balances these competing requirements through careful selection of material properties and geometric dimensions.

Inventive Principle:

Principle #35Parameter changes

3Strength

If conventional rigid connectors are used, then structural strength is improved, but adaptability to imperfect geometry deteriorates

Engineering Contradiction:

Improvestructural strengthVSAvoidadaptability to imperfect geometry

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The pin transitions from a rigid structure to a flexible structure with controlled deformation characteristics. This allows the connector to adapt to imperfect ferrule geometry while maintaining sufficient structural strength through optimized material properties and cross-sectional geometry.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The pin is designed to dynamically adapt its shape during insertion, deforming to accommodate angular and diametral errors. This dynamic flexibility is achieved through specific material selection and geometric design that allows controlled deformation while maintaining structural integrity.

Inventive Principle:

Principle #15Dynamics

4Ease of operation

If flexible pins are used, then ease of operation is improved, but device complexity increases

Engineering Contradiction:

Improveease of connectionVSAvoidconnector complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The pin's flexibility parameters are optimized to provide sufficient give for easy insertion while preventing excessive deformation that would complicate the connection process. This balance is achieved through specific material selection and geometric design of the pin structure.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution enables reliable optical connections by accommodating imperfect ferrule geometry, reducing the risk of damage and misalignment, and ensuring consistent and efficient light transmission across optical fibers.

Implementation Method 1

The flexible pin is flexible both in bending and radially or may be flexible either in bending or radially to accommodate variations in fiber optic ferrules

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11009665B2Multi-fiber fiber optic connection system with flexible, insertable pins

Publication Date: 2021.05.18 COMMSCOPE TECHNOLOGIES LLC

AI summary

A flexible pin for use in a male fiber optic connector is flexible both in bending and radially to accommodate variations in fiber optic ferrules of the male fiber optic connector and a female fiber optic connector. The flexibility may accommodate angular errors of the male and the female fiber optic connectors. The flexibility may also accommodate diametral errors of the flexible pin of the male fiber optic connector and diametral errors in a pin hole of the female fiber optic connector. The flexibility is sufficient that a connector spring or spring clamp can mate mating faces of the male and the female fiber optic connectors with the errors present. In certain embodiments, the flexible pin is a removable pin that includes a latch. The removable pin can be installed and removed from a fiber optic connector without disassembling a ferrule from a connector housing of the fiber optic connector.